Movable Optical Elements in DLP Exposure Molding
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Solution Overview
Problem
Conventional DLP additive manufacturing is limited in molding large objects due to restricted projection range, resulting in reduced accuracy, velocity, and quality due to the need for dividing large projection images and moving heavy projection light sources, which causes errors and lowers molding quality.
Innovation Solution
An exposure molding device and method that utilize movable optical elements and optical compensating elements to expand the molding range, ensuring accuracy, resolution, and velocity by moving lightweight optical components and calculating their velocity and route based on exposure time, thereby preventing distortion and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the projection area is expanded to mold large objects, then the molding range is improved, but the resolution and optical power in unit area deteriorate
Solution Approach 1:
The patent divides the large projection area into multiple sub-areas, with each DLP projection light source responsible for projecting a specific sub-image to a corresponding sub-area. This segmentation allows the system to maintain high resolution in each sub-area while collectively covering a large projection area, resolving the contradiction between expanded molding range and maintained resolution.
2Area of stationary object
If the projection light source is moved to expand projection area, then the molding range is improved, but the velocity and accuracy of moving deteriorate due to large weight
Solution Approach 1:
The patent segments the projection system into multiple fixed DLP projection light sources, each responsible for a specific sub-area. This eliminates the need to move heavy projection light sources while still achieving large projection area coverage through coordinated projection to multiple sub-areas, resolving the contradiction between expanded range and maintained positioning accuracy.
Solution Approach 2:
Instead of moving the projection light source to cover different areas (traditional approach), the patent inverts the approach by using multiple fixed projection light sources that simultaneously cover different sub-areas. This inversion eliminates movement-related accuracy issues while achieving the same goal of expanded projection coverage.
3Area of stationary object
If multiple sub-images are composed to form large projection images, then the molding range is improved, but the molding quality deteriorates due to image composing errors
Solution Approach 1:
The patent assigns each DLP projection light source to project a specific sub-image to a corresponding sub-area, with each projection light source independently controlling its sub-area. This segmentation approach eliminates the need for complex image composing and reduces positioning errors, thereby maintaining high molding quality while achieving large projection area coverage.
4Area of stationary object
If the projection light source is moved to cover large areas, then the molding range is improved, but the velocity of molding deteriorates due to moving inertia
Solution Approach 1:
The patent divides the projection system into multiple fixed DLP projection light sources, each projecting to a specific sub-area simultaneously. This eliminates the time-consuming movement of heavy projection light sources while maintaining large projection area coverage, thereby significantly improving molding velocity without sacrificing range.
Solution Approach 2:
The patent enables simultaneous projection to multiple sub-areas by multiple fixed projection light sources, allowing continuous and parallel molding operations across the entire large projection area. This eliminates the sequential movement and repositioning required in traditional systems, maintaining continuous useful action and improving overall molding velocity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively expands the molding range while enhancing accuracy, velocity, and quality by compensating for optical path differences and optimizing the movement of optical elements, resulting in improved molding performance.
Implementation Method 1
The DLP additive manufacturing is applying projection technology to project layered images of objects on photopolymer in sequence, and the layers are stacked for molding
Data Source
AI summary
An exposure molding device comprises an exposure tank, a working platform, and an optical system. The exposure tank has a first surface and a second surface. The working platform is disposed relative to the first surface. The optical system disposed relative to the second surface comprises a light emission element and an optical assembly. The light emission element emits light along an optical path. The optical assembly comprises a light transparent element, a first optical element, and a first transmission mechanism. The light transparent element is disposed on the optical path, the first optical element is disposed behind the light transparent element on the optical path, and the first transmission mechanism is disposed along a first direction and connected with the first optical element for driving the first optical element to move along the first direction. The molding range is expanded. The accuracy, velocity and quality of molding are enhanced.